Fiber structure and method for producing same

Abstract

In order to provide a fiber structure and a method for producing the same in which a glass fiber single filament can be applied to a complex woven fabric such as a Jacquard fabric, this fiber structure has a plurality of warp threads and a plurality of weft threads that are interlaced with the plurality of warp threads, and the fiber structure is characterized by comprising a Jacquard fabric in which the plurality of warp threads are made of a resin and the plurality of weft threads include a glass fiber single filament.

Description

Fiber structure and method for producing the same

[0001] The present invention relates to a fiber structure and a method for producing the same.

[0002] For example, Patent Document 1 (JP 2023-63052 A) discloses a composite comprising a resin molded article containing a thermoplastic resin and a fiber structure at least partially in contact with the resin molded article and having a breaking elongation of 50.0% or more, in order to provide a composite that is comfortable to wear on the body and has excellent adhesion between the resin molded article and the fiber structure. Here, the fibers constituting the fiber structure may be glass fibers, and the form of the fiber structure may be a woven fabric.

[0003] Patent Document 1 does not specify the form in which the glass fiber is used, but since a single glass fiber thread is strong but fragile, it is not suited to manufacturing processes in which stresses such as bending and stretching are applied. For example, even if it is put through a loom, it can be used for simple fabrics such as plain weave, twill weave, and sash weave, but it is not used for complex fabrics such as jacquard weave.

[0004] Furthermore, fabrics using glass fiber include, for example, various nonwoven fabrics and woven fabrics in which both the warp and weft are made of glass fiber, but their use is generally limited to attaching them to the backside of reinforced objects in order to reinforce them, and the texture obtained by using the glass fiber has not been actively utilized in the texture or surface appearance of the final product.

[0005] Japanese Patent Application Laid-Open No. 2023-63052

[0006] Contrary to this common technical knowledge in the prior art, the present inventors attempted to supply glass fiber yarn and resin yarn to a jacquard loom to see if they could weave a fabric, and contrary to their expectations, they were able to produce a woven fabric. Furthermore, when they converted some of the resin yarn into heat-shrinkable yarn and heated it, they discovered that, depending on the conditions, it was possible to obtain fabric with a texture and appearance never before seen.

[0007] In view of the above, the present invention provides a fiber structure made of jacquard weave, which allows glass fiber single yarns to be used in complex woven fabrics such as jacquard weave, and a method for producing the same.

[0008] The present invention, which has been obtained based on the above findings, provides a textile structure made of a jacquard weave, which has a plurality of warp yarns and a plurality of weft yarns intertwined with the plurality of warp yarns, wherein the plurality of warp yarns are made of resin, and the plurality of weft yarns include glass fiber monofilaments.

[0009] In the fiber structure of the present invention having the above configuration, it is preferable that some of the plurality of warp threads are shrinkable warp threads, and that the shrinkable warp threads have a skip portion at least at one point in their length direction, which skips over a predetermined number of adjacent weft threads.

[0010] In the fiber structure of the present invention having the above configuration, it is preferable that the number of the glass fiber monofilaments contained per 1 cm of width of the fabric of the fiber structure is 20 to 120.

[0011] In the fiber structure of the present invention having the above configuration, it is preferable that the glass fiber single yarn has a denier of 30 to 3000.

[0012] The present invention also provides a method for manufacturing a textile structure consisting of a jacquard weave, the method comprising: weaving a textile fabric in a predetermined pattern using a plurality of warp threads and a plurality of weft threads intertwined with the plurality of warp threads; and applying a specific treatment to the woven textile fabric, wherein the plurality of warp threads are made of resin.

[0013] In the method for producing a fiber structure of the present invention having the above configuration, it is also preferable that some of the plurality of warp threads are shrinkable warp threads, the shrinkable warp threads have skip portions at least at one location in the length direction that skip over a predetermined number of adjacent weft threads, and the plurality of weft threads include glass fiber monofilaments.

[0014] According to the present invention, it is possible to provide a fiber structure made of jacquard weave, in which glass fiber single yarns can be used for complex woven fabrics such as jacquard weave, and a method for producing the same.

[0015] 1 is a schematic diagram showing an example of the weave of a textile structure 1 made of a jacquard weave according to a representative embodiment of the present invention. 2 is an enlarged photograph showing an example of the weave of the textile structure 1.

[0016] Hereinafter, a jacquard woven textile structure and a method for producing the same according to a representative embodiment of the present invention will be described in detail with reference to the drawings. Note that the drawings are intended to conceptually explain the present invention, and therefore, for ease of understanding, dimensions, ratios, or numbers may be exaggerated or simplified as necessary, and the present invention is not limited thereto.

[0017] 1. Structure of the textile structure 1 The structure of a textile structure 1 made of a jacquard weave will be described with reference to Fig. 1 and Fig. 2. Fig. 1 is a schematic diagram showing an example of the structure of the textile structure 1. Fig. 2 is an enlarged photograph showing an example of the structure of the textile structure 1.

[0018] The fiber structure 1 is a fabric made of woven fabric. That is, the fiber structure 1 has a plurality of warp threads 10 and a plurality of weft threads 20 intertwined with the plurality of warp threads 10. The plurality of warp threads 10 is a collective term for normal warp threads (other warp threads) 11 and shrinkable warp threads 12, which will be described later, and are made of resin. The plurality of weft threads 20 is a collective term for normal weft threads (other weft threads) 21 and glass fiber single threads 22, which will be described later, and the other weft threads 21 are made of resin. The fabric constituting the woven fabric of the fiber structure 1 may be single-ply or double-ply.

[0019] The plurality of warp threads 10 include normal warp threads 11 and shrinkable warp threads 12. The normal warp threads 11 may be made of chemical fibers or resin fibers. The normal warp threads 11 can be made of a resin material such as polyester.

[0020] The shrinkable warp threads 12 shrink more in the longitudinal direction than the normal warp threads 11 when subjected to a specific treatment such as heating, and can also be called heat-shrinkable threads. For example, the shrinkable warp threads 12 are composed of a core and a covering thread wound around the core. The core can be made of a material such as polyurethane that shrinks significantly in the longitudinal direction when heated to a predetermined temperature. The covering thread can be made of the same material as the normal warp threads 11, such as polyester.

[0021] Each shrinkable warp yarn 12 in the fiber structure 1 has a jump section 12A at least at one location in the length direction, which jumps over a predetermined number of adjacent weft yarns. The jump section 12A may be exposed on the front side or hidden on the back side of the fiber structure 1. The jump sections 12A are arranged according to a predetermined pattern.

[0022] Next, the weft thread 20 includes a glass fiber (long fiber) single yarn 22. For example, a single yarn of E-glass fiber can be suitably used as the weft thread 20, but is not limited to this. Also, the other weft thread (normal weft thread) 21 can be made of the same material as the normal warp thread 11, for example, polyester.

[0023] In the fiber structure 1, when a specific treatment such as heating is applied, the shrinkable warp yarns 12 shrink more in the length direction than the normal warp yarns 11. That is, the shrinkable warp yarns 12 shrink more in the jump section 12A, and the entire fiber structure 1 shrinks in the warp direction. This allows a three-dimensional shape and pattern to be formed in the fiber structure 1 according to a preset pattern. Furthermore, the glass fiber contained in the weft yarns 20 ensures sufficient strength. Moreover, the hardness of the fiber structure 1 can be adjusted.

[0024] Next, specific examples of materials constituting the fiber structure 1 will be given. As the normal warp threads 11, polyester 50 to 150 (preferably 70 to 80) denier (36 filaments) can be used. As the shrinkable warp threads 12, polyester wound Marlon (size processed) can be used. The shrinkable warp threads 12 can be 50 to 150 denier. The ratio of the normal warp threads 11 to the shrinkable warp threads 12 can be about 10,000 for the former and about 2,000 for the latter.

[0025] The glass fiber monofilament 22 used as the weft can be 30 to 3,000 denier. The glass fiber monofilament 22 can be wound and wound. Furthermore, for single-ply fabrics, approximately 10 to 50 fibers per cm can be woven, and for double-ply fabrics, approximately 30 to 120 fibers per cm can be woven. Fabrics cannot be woven with a density of less than 10 to 120 fibers per cm. A density of less than 10 fibers per cm results in a coarse fabric that loses its shape and is therefore difficult to fabricize. On the other hand, a density of more than 120 fibers per cm results in a dense fabric that is too stiff, impairing flexibility and processability, making it difficult to fabricate. Furthermore, to more reliably achieve the effects of the present invention, it is preferable to use glass fiber monofilament 22 of 100 to 300 denier and a density of 20 to 100 fibers per cm.

[0026] As a type of glass fiber, E-glass can be preferably used. The composition of E-glass is roughly as follows: SiO ２ 52~56(%) Al ２ O ３ 12-16 (%) CaO, MgO 20-25 (%) R ２ O 0-0.8 (%) B ２ O ３ 5 to 10 (%)

[0027] The glass fiber in this embodiment is a single yarn obtained by twisting a strand of filaments of 4.0 μm to 7.4 μm, and glass fiber having the following characteristics can be particularly preferably used: [Glass fiber example 1] Filament diameter: 5.3 μm Number of filaments: 200 Number of twists: 1.0 / 25 mm Tex count: 11.2 g / 1000 m Length per mass: 89.2 km / kg

[0028] [Glass fiber example 2] Filament diameter 6.4 μm Number of filaments 400 Number of twists 1.0 / 25 mm Tex count 33.7 g / 1000 m Length per mass 29.6 km / kg

[0029] Furthermore, the glass fiber single yarn 22 may have one turn (Z direction) per 25 mm for a 100 denier equivalent, and one turn (Z direction) per 25 mm for a 300 denier equivalent.

[0030] 2. Method for Producing the Fiber Structure 1 Next, a method for producing the fiber structure 1 will be described.

[0031] The method for manufacturing the fiber structure 1 includes a step of weaving a fabric using a plurality of warp yarns 10 and a plurality of weft yarns 20 interlaced with the plurality of warp yarns 10 in a predetermined pattern (weaving step), and a step of applying a specific treatment to the woven fabric. Here, heating is used as the specific treatment, so the latter step is referred to as the heating step. However, the specific treatment may be any treatment that can shrink the shrinkable warp yarns 12, and other treatments such as immersion in a chemical may also be used.

[0032] The warp threads 10 include normal warp threads 11 and shrinkable warp threads 12. The weft threads 20 include glass fiber single yarns 22 and other weft threads 21. In the weaving process of this embodiment, for example, wound warp threads 10 and weft threads 20 are used and fed to a Jacquard loom to create a Jacquard weave. Before the warp threads 10 and weft threads 20 are hung on the loom, the necessary pattern paper is prepared, the yarns are dyed, and warping is performed.

[0033] In the heating step, various methods can be used as long as they can heat the woven fabric. For example, an iron, steam, a hot water bath, etc. can be used. Heat is applied by these methods to shrink the shrinkable warp yarns 12, thereby giving the fabric a three-dimensional structure. The heating conditions can be adjusted appropriately depending on the specifications of the fiber structure 1. For example, steam at 100°C to 180°C can be applied to the fiber structure 1 for about 1 second to 1 minute, preferably 2 to 3 seconds to 30 seconds.

[0034] The fiber structure 1 thus obtained can be used to reproduce fine and delicate patterns with a high degree of freedom using jacquard weaving technology. Since patterns can be created by changing the structure of the fabric, not only does it create a three-dimensional effect and thickness in the fabric, but the shrinkage of the fabric itself also enhances the three-dimensional effect.

[0035] Furthermore, the glass fiber weft yarns can provide sufficient strength to the fiber structure 1. Moreover, the hardness of the fiber structure 1 can be adjusted by adjusting the composition of the shrinkable warp yarns 12 and the heating conditions.

[0036] Therefore, the fiber structure 1 can be used for various purposes and can be applied to the front side to be decorated. For example, the fiber structure 1 can be used for lighting, interior decoration, furniture, etc. In this regard, in conventional technology, although yarn containing glass fiber has been woven on a loom, it has only been applied to relatively simple fabrics such as plain weave, twill weave, and satin weave. In other words, there has been no idea of ​​jacquard weaving using yarn containing glass fiber. Furthermore, conventionally, fabrics made from yarn containing glass fiber have only been used by attaching them to the back side of an object for reinforcement, etc., and this fiber fabric has not been used as a front side pattern.

[0037] While the representative embodiments of the present invention have been described above, the present invention is not limited to these embodiments, and various design modifications are possible, and all such modified design aspects are included within the technical scope of the present invention. For example, metal fibers such as aluminum fibers or carbon fibers may be used in combination with glass fibers.

[0038] REFERENCE SIGNS LIST 1 Fiber structure (fabric) 11 Regular warp yarn (other warp yarn) 12 Shrinkable warp yarn 12A Jump section 21 Regular weft yarn (other weft yarn) 22 Glass fiber single yarn

Claims

1. A textile structure having a plurality of warp threads and a plurality of weft threads intersecting with the plurality of warp threads, the plurality of warp threads being made of resin, and the plurality of weft threads including single yarns of glass fiber, the textile structure being made of a jacquard weave.

2. The fiber structure according to claim 1, wherein a portion of the plurality of warp threads are shrinkable warp threads, and the shrinkable warp threads have a skip portion at least at one point in the length direction thereof that skips over a predetermined number of adjacent weft threads.

3. The fiber structure according to claim 1 or 2, wherein the number of said glass fiber monofilaments per 1 cm of width of the fabric of said fiber structure is 20 to 120.

4. The fiber structure according to claim 1 or 2, wherein the glass fiber single yarn has a denier of 30 to 3,000.

5. A method for manufacturing a textile structure comprising a jacquard weave, the method comprising: weaving a plurality of warp threads and a plurality of weft threads intersecting with the plurality of warp threads into a textile fabric in a preset pattern; and applying a specific treatment to the woven textile fabric, the plurality of warp threads being made of resin, and the plurality of weft threads including single yarns of glass fiber.

6. A method for producing a fiber structure according to claim 5, characterized in that a part of the plurality of warp threads is a shrinkable warp thread, and the shrinkable warp thread has a skip portion at least at one point in the length direction thereof that skips over a predetermined number of adjacent weft threads.

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